Cooling system with integrated fill and drain pump

ABSTRACT

A cooling system is provided which includes, for instance, a coolant circulation loop, one or more primary coolant pumps, and a fill and drain pump. The primary coolant pump(s) is coupled to facilitate circulating coolant through the coolant circulation loop, and the fill and drain pump facilitates selective filling of the cooling system with the coolant, or draining of the coolant from the cooling system. The fill and drain pump is integrated with the cooling system as a backup coolant pump to the primary coolant pump(s), and circulates the coolant through the coolant circulation loop responsive to an error in the primary coolant pump(s). The primary coolant pump(s) and fill and drain pumps may be different types of pumps, and the cooling system further includes a control system for automatically activating the fill and drain pump upon detection of an error in the primary coolant pump(s).

BACKGROUND

The power dissipation of integrated circuit chips, and the modulescontaining the chips, continues to increase in order to achieveincreases in processor performance. This trend continues to pose coolingchallenges at the module and system levels.

In many large server applications, processors along with theirassociated electronics (e.g., memory, disk drives, power supplies, etc.)are packaged in removable drawer configurations stacked within anelectronics rack or frame comprising information technology (IT)equipment. In other cases, the electronics may be in fixed locationswithin the rack or frame. Conventionally, the components have beencooled by air moving in substantially parallel airflow paths, usuallyfront-to-back, impelled by one or more air moving assemblies (e.g.,axial or centrifugal fans). In some cases it has been possible to handleincreased power dissipation within a single drawer or system byproviding greater airflow, for example, through the use of more powerfulair moving assemblies or by increasing the rotational speed (i.e., RPMs)of the fan mechanisms. However, this approach is becoming problematic atthe different cooling levels. As an enhancement, liquid-cooling is anattractive technology to selectively manage the higher heat fluxes. Theliquid absorbs the heat dissipated by the components/modules in anefficient manner. Typically, the heat is ultimately transferred from theliquid coolant to a heat sink, whether air or other liquid-based.

BRIEF SUMMARY

The shortcomings of the prior art are addressed and additionaladvantages are provided through the provision, in one aspect, of asystem which includes a cooling system for cooling one or moreelectronic components. The cooling system includes: a coolantcirculation loop; at least one primary coolant pump coupled tofacilitate circulating coolant through the coolant circulation loop; anda fill and drain pump to facilitate selective filling of the coolingsystem with the coolant, or draining of the coolant from the coolingsystem, the fill and drain pump being integrated with the cooling systemas a backup coolant pump to the at least one primary coolant pump, andthe fill and drain pump circulating the coolant through the coolantcirculation loop responsive to an error in the at least one primarycoolant pump.

In another aspect, a cooled electronic assembly is provided whichincludes multiple electronic systems to be cooled, and a cooling systemfor cooling the multiple electronic systems. The cooling systemincludes: a coolant circulation loop comprising a coolant supplymanifold and a coolant return manifold; multiple cooling assembliescoupled in parallel-fluid communication between the coolant supplymanifold and the coolant return manifold to receive coolant from thecoolant supply manifold, and exhaust coolant to the coolant returnmanifold, the multiple cooling assemblies being associated with themultiple electronic systems to facilitate removal of heat from themultiple electronic systems to coolant within the multiple coolingassemblies; a heat exchange assembly coupled in fluid communication withthe coolant circulation loop to dissipate heat from the coolant passingtherethrough; at least one primary coolant pump coupled to facilitatecirculating coolant through the coolant circulation loop; and a fill anddrain pump to facilitate selective filling of the cooling system withthe coolant, or draining of the coolant from the cooling system, thefill and drain pump being integrated with the cooling system as a backupcoolant pump to the at least one primary coolant pump, the fill anddrain pump circulating the coolant through the coolant circulation loopbased on an error in the at least one primary coolant pump.

In a further aspect, a method is provided which includes providing acooling system, the providing including: providing a coolant circulationloop; providing at least one primary coolant pump coupled to facilitatecirculating coolant through the coolant circulation loop; andintegrating a fill and drain pump with the cooling system to facilitateselective filling of the cooling system with the coolant, or draining ofthe coolant from the cooling system, the fill and drain pump beingintegrated with the cooling system as a backup coolant pump to the atleast one primary coolant pump, the fill and drain pump circulating thecoolant through the coolant circulation loop responsive to an error inthe at least one primary coolant pump.

Additional features and advantages are realized through the techniquesof the present invention. Other embodiments and aspects of the inventionare described in detail herein and are considered a part of the claimedinvention.

BRIEF DESCRIPTION OF THE DRAWINGS

One or more aspects of the present invention are particularly pointedout and distinctly claimed as examples in the claims at the conclusionof the specification. The foregoing and other objects, features, andadvantages of the invention are apparent from the following detaileddescription taken in conjunction with the accompanying drawings inwhich:

FIG. 1 depicts one embodiment of a raised floor layout of an air-cooleddata center, which may employ one or more cooling systems, in accordancewith one or more aspects of the present invention;

FIG. 2 is a cross-sectional elevational view of one implementation of anelectronics rack for a data center, which may employ a cooling system,in accordance with one or more aspects of the present invention;

FIG. 3 is a schematic of one embodiment of a cooled electronics assemblyor rack having multiple electronic systems and a cooling system, inaccordance with one or more aspects of the present invention;

FIG. 4 is a schematic of another embodiment of a cooled electronicsassembly having multiple electronic systems and a cooling system with,in part, an integrated fill and drain pump, in accordance with one ormore aspects of the present invention;

FIG. 5A depicts one detailed embodiment of a partially-assembled, cooledelectronic assembly comprising multiple electronic systems and a coolingsystem, in accordance with one or more aspects of the present invention;

FIG. 5B is an enlarged depiction of one embodiment of the multifunctioncoolant manifold structure of the cooling system of FIG. 5A, inaccordance with one or more aspects of the present invention;

FIG. 6 is a partial cross-sectional elevational view of the cooledelectronic assembly of FIG. 5A, in accordance with one or more aspectsof the present invention;

FIG. 7 is a further block diagram depiction of the cooled electronicassembly of FIG. 5A, illustrating components of the cooling system whichare (in one embodiment) concurrently field-replaceable (CF), as well ascomponents which are non-concurrently field-replaceable (NCF), inaccordance with one or more aspects of the present invention;

FIG. 8A is an operational schematic of one embodiment of the cooledelectronic assembly of FIG. 5A, in accordance with one or more aspectsof the present invention;

FIG. 8B depicts one embodiment of a control system process for, in part,activating the fill and drain pump as a backup coolant pump to circulatecoolant through the coolant circulation loop responsive to an error inthe primary coolant pump(s), in accordance with one or more aspects ofthe present invention;

FIG. 9 is a partial depiction of the cooled electronic assembly of FIG.5A, and a fill/drain container to be used in a coolant fill process orcoolant drain process, in accordance with one or more aspects of thepresent invention;

FIG. 10A depicts the assembly of FIG. 9, with the hoses shown connectedto facilitate a coolant fill process, in accordance with one or moreaspects of the present invention;

FIG. 10B depicts one embodiment of a coolant fill process using theassembly of FIG. 10A, in accordance with one or more aspects of thepresent invention;

FIG. 11A depicts the assembly of FIG. 9, with the hoses shown connectedto facilitate a coolant drain process, in accordance with one or moreaspects of the present invention;

FIG. 11B depicts one embodiment of a coolant drain process using theassembly of FIG. 11A, in accordance with one or more aspects of thepresent invention; and

FIG. 12 depicts one embodiment of a computer program productincorporating one or more aspects of the present invention.

DETAILED DESCRIPTION

Reference is made below to the drawings, wherein the same or similarreference numbers used throughout different figures designate the sameor similar components.

As shown in FIG. 1, in one implementation of a raised floor layout of anair-cooled data center 100, multiple electronics racks 110 are disposedin one or more rows. Note that “electronics rack”, “rack unit”, “rack”,“information technology (IT) infrastructure”, etc., may be usedinterchangeably herein, and unless otherwise specified, include anyhousing, frame, support, structure, compartment, etc., having one ormore heat-generating components of a computer system, electronic system,IT system, etc. A computer installation such as depicted in FIG. 1 mayhouse several hundred, or even several thousand microprocessors. In thearrangement of FIG. 1, chilled air enters the computer room via floorvents from a supply air plenum 145 defined between a raised floor 140and a base or sub-floor 165 of the room. Cooled air is taken in throughlouvered covers at air inlet sides 121 of the electronics racks andexpelled through the back (i.e., air outlet sides 131) of theelectronics racks. Electronics racks 110 may have one or more air-movingdevices (e.g., axial or centrifugal fans) to provide forcedinlet-to-outlet air flow to cool the electronic components within therack units. The supply air plenum 145 provides (in one embodiment)conditioned and cooled air to the air-inlet sides of the electronicsracks via perforated floor tiles 160 disposed in a “cold” aisle of thecomputer installation. The cooled air is supplied to plenum 145 by oneor more air conditioning units 150, also disposed within data center100. Room air may be taken into each air conditioning unit 150 near anupper portion thereof. This room air may comprise (in part) exhaustedair from the “hot” aisles of the computer installation defined byopposing air outlet sides 131 of the electronics racks 110.

FIG. 2 depicts (by way of example) one embodiment of an electronics rack110 with a plurality of electronic systems 201 to be cooled. In theembodiment illustrated, electronic systems 201 are air-cooled by coolairflow 202 ingressing via air inlet side 121, and exhausting out airoutlet side 131 as heated airflow 203. By way of example, one or moreair-moving assemblies 208 may be provided at the air inlet sides ofelectronic systems 201 and/or one or more air-moving assemblies 209 maybe provided at the air outlet sides of electronic systems 201 tofacilitate airflow through the individual systems 201 as part of thecooling apparatus of electronics rack 110. For instance, air-movingassemblies 208 at the air inlets to electronic systems 201 may be orinclude axial fan assemblies, while air-moving assemblies 209 disposedat the air outlets of electronic systems 201 may be or includecentrifugal fan assemblies. One or more electronic systems 201 mayinclude heat-generating components to be cooled of, for instance, anelectronic subsystem, and/or information technology (IT) equipment. Moreparticularly, one or more of the electronic systems 201 may include oneor more processors and associated memory.

In one embodiment, electronics rack 110 may also include, by way ofexample, one or more bulk power assemblies 204 of an AC to DC powersupply assembly. AC to DC power supply assembly further includes, in oneembodiment, a frame controller, which may be resident in the bulk powerassembly 204 and/or in one or more electronic systems 201. Alsoillustrated in FIG. 2 is one or more input/output (I/O) drawer(s) 205,which may also include a switch network. I/O drawer(s) 205 may include,as one example, PCI slots and disk drivers for the electronics rack.

In the depicted implementation, a three-phase AC source feeds power viaan AC power supply line cord 206 to bulk power assembly 204, whichtransforms the supplied AC power to an appropriate DC power level foroutput via distribution cable 207 to the plurality of electronic systems201 and I/O drawer(s) 205. The number of electronic systems installed inthe electronics rack is variable, and depends on customer requirementsfor a particular system. Note that the particular electronics rack 110configuration of FIG. 2 is presented by way of example only, and not byway of limitation. In particular, FIGS. 3-12 depict, in part, otheralternate implementations of an electronics rack and cooling approaches,in accordance with one or more aspects of the present invention.

Referring first to FIG. 3, a schematic diagram is presented of oneembodiment of a cooled electronic assembly configured as a cooledelectronics rack 110′, which includes multiple electronic systems 301and a cooling system, which may be disposed fully or partially internalto the electronics rack, or in an alternate implementation, partiallyexternal, and even remote from the electronics rack. In the depictedimplementation, electronic systems 301 each have an associated coolingassembly (or heat removal structure) of the cooling system. By way ofexample, one or more of the cooling assemblies may comprise one or morecoolant-cooled cold plates, or one or more coolant-immersion housingsdepending, for instance, whether indirect or direct liquid-assistedcooling is desired. The cooling system further includes a coolant supplymanifold 310 and a coolant-commoning manifold 320, with the multiplecooling structures being coupled in parallel fluid communication betweencoolant supply manifold 310 and coolant-commoning manifold 320 toreceive coolant from the coolant supply manifold, and exhaust coolant tothe coolant-commoning manifold. Note that one example of the coolant iswater, or an aqueous-based solution. However, the concepts disclosedherein are readily adapted to use with other types of coolant. Forexample, the coolant may comprise a brine, a dielectric liquid, afluorocarbon liquid, a metal liquid, or other coolant, or refrigerant,while still maintaining the advantages and unique features of thepresent invention.

FIG. 3 depicts an example of a closed-loop cooling system, with multiplecontrol and monitor components that allow the system to operatereliably. These components include one or more de-aerators 321 to removedissolved gasses from the coolant, a coolant expansion structure 322 toaccommodate expansion of coolant within the cooling system, a reservoir323, one or more level sensors 324 associated with reservoir 323 tosense level of coolant within the cooling system, a vacuum breaker 325coupled to the coolant loop of the cooling system to prevent cavitationof the pumping assembly, and a pressure-relieve valve 326 associatedwith the coolant loop to ensure that the cooling system does notover-pressurize. A fill port 328 may be provided at the top of thecooling system, and a fill/drain port 329 may be provided in a lowerportion of the cooling system. As shown, reservoir 323 functions tosupply coolant to a distribution manifold 330 of a pumping assembly,which includes multiple primary coolant pumps 335, primary coolant pump1, primary coolant pump 2, each with an associated downstream checkvalve 336. Further, the pumping assembly includes a return manifold 340.As illustrated, the primary coolant pumps 335 of the pumping assemblyare coupled in parallel fluid communication between distributionmanifold 330 and return manifold 340. In one implementation, the primarycoolant pumps 335 are modular pumping units (MPUs), which may beindividually, selectively replaced concurrent with continued operationof the cooling system of the cooled electronic assembly depicted. Notethat, in one implementation, the components of the cooling system ofFIG. 3 are discrete components which fulfill the above-describedfunctions.

As illustrated, the cooling system further includes a heat removalsection 350, coupled in fluid communication between return manifold 340of the pump assembly and coolant supply manifold 310. By way of example,heat removal section 350 includes one or more coolant-to-air heatexchangers with one or more associated fan mechanisms (e.g., axial orcentrifugal fans) to facilitate air-cooling of coolant within the heatexchanger(s) by flowing cooled air 300 across heat removal section 350.As used herein, “coolant-to-air heat exchanger” means any heat exchangemechanism characterized as described herein, across which air passes andthrough which coolant, such as liquid coolant, can circulate; andincludes, one or more discrete heat exchangers, coupled either in seriesor in parallel. A coolant-to-air heat exchanger may comprise, forexample, one or more coolant flow paths, formed of thermally conductivetubing (such as copper or other tubing) thermally coupled to a pluralityof fins across which air passes. Size, configuration and construction ofthe coolant-to-air heat exchanger can vary without departing from thescope of the invention disclosed herein.

After passing across heat removal section 350, the heated air egressesfrom the rack unit as heated air 300′. Note that in an alternateembodiment, the heat removal section could include one or morecoolant-to-coolant heat exchangers, or one or more liquid-to-liquid heatexchangers, to reject heat from the coolant circulating through thecooling system. For instance, the heat could be rejected tofacility-chilled water where available, rather than to cooled air 300.

In operation, heat generated within the electronic systems 301 isextracted by coolant flowing through (for example) respective coolingstructures associated therewith, such as cold plates, and is returnedvia the coolant-commoning manifold 320 and the active primary coolantpump(s) 335, for example, for rejection of the heat from the coolant tothe cooled ambient air 300 passing across the heat exchanger in heatremoval section 350. In one implementation, only one primary coolantpump 335 may (depending on the mode) be active at a time, and thecoolant pump redundancy allows for, for example, servicing orreplacement of an inactive pumping unit from the cooling system, withoutrequiring shut-off of the electronic systems being cooled. By way ofspecific example, quick connect couplings may be employed, along withappropriately sized and configured hoses to couple, for example, theheat exchanger, cold plates, supply and return manifolds, reservoir andpumping units. Redundant fan mechanisms, such as redundant centrifugalfans, with appropriate, redundant drive cards or controllers, may bemounted to direct cooled air 300 across the heat exchanger(s) of theheat removal section. These controllers may be in communication with asystem-level controller (not shown), in one embodiment. In one normalmode implementation, the multiple fan mechanisms may be running at thesame time.

Note again that, although described above with reference to one or morecoolant-to-air heat exchangers, the cooling system(s) disclosed hereinmay provide pumped coolant (such as water) for circulation throughvarious types of heat exchange assemblies, including one or morecoolant-to-air heat exchangers, one or more coolant-to-coolant heatexchangers, a rack-mounted door heat exchanger, a coolant-to-refrigerantheat exchanger, etc. Further, the heat exchange assembly may comprisemore than one heat exchanger, including more than one type of heatexchanger, depending upon the implementation. The heat exchangeassembly, or more generally, heat removal section, could be within thecooled electronics rack, or positioned remotely from the rack.

In FIG. 3, a closed-loop cooling system is illustrated whichincorporates a number of components that ensure that the cooling systemworks reliably. These include, but are not necessarily limited to: acoolant reservoir; coolant level sensors; a coolant expansion region;one or more vacuum breakers; one or more pressure-relieve valves; apumping assembly which may include multiple modular pumping units;distribution and return manifolds for pump flow through one or moreparallel-coupled pumping units of the pump assembly; check valves toprevent back flow through one or more inactive pumps of the pumpassembly; a separate de-aerator facility to remove air or other gassesfrom the coolant within the cooling system; a supply manifold todistribute coolant to multiple cooling structures coupled in parallel; acoolant supply manifold; a return manifold to receive exhaust coolantfrom the multiple cooling structures; a heat removal section ormechanism, such as a coolant-to-air heat exchanger; and fill and drainports for filling and draining the cooling system.

In one implementation, the above-noted components of the cooledelectronic assembly, and in particular, the noted components of thecooling system, may be discrete components obtained, at least in part,as commercially available components. However, implementing the coolingsystem in this manner may add cost, space, and complexity to the coolingsystem, as well as to the resultant cooled electronic assembly. Inaccordance with aspects of the present invention, many of theabove-noted structures or functions may be integrated (or combined)within a single, novel, multifunction coolant manifold structure.

For instance, in one embodiment, the multifunction coolant manifoldstructure may include or provide: a coolant reservoir; one or morecoolant level sensors; a coolant expansion region; one or more vacuumbreakers to prevent pump cavitation; one or more pressure-relief valvesto ensure the cooling system does not over-pressurize; a distributionmanifold to distribute coolant to the pumping assembly; a de-aeratorfacility to remove air and other gasses from the coolant within thecooling system; a coolant-commoning manifold to common exhaust coolantfrom multiple cooling structures; as well as a fill port for the coolingsystem. Advantageously, combining components of the cooling system intoa single, multipurpose manifold structure saves cost, reduces space, andreduces complexity of the cooling system, as well as of the resultantcooled electronic assembly.

FIG. 4 is a schematic depiction of one embodiment of a cooled electronicassembly configured as a cooled electronics rack 110″, similar to theabove-described cooled electronics rack 110′ of FIG. 3. One significantdifference in the assembly configuration of FIG. 4, however, is theprovision of a multifunction coolant manifold structure 400, whichintegrates many of the functions and components described above inconnection with the cooling system provided for the cooled electronicassembly of FIG. 3. In particular, as illustrated in FIG. 4, themultifunction coolant manifold structure 400 is shown to include, in oneembodiment, a coolant-commoning manifold 320′, a de-aerator facility321′, a coolant expansion region 322′, a coolant reservoir 323′, one ormore coolant level sensors 324′, one or more vacuum breakers 325′, oneor more pressure-relieve valves 326′, a distribution manifold 330′ forthe pump assembly, as well as a fill port 328′. As described furtherbelow in connection with the embodiments of FIG. 5A-5B, these componentsare differently configured, however, and/or alternately implemented incomparison to the discrete components employed in the cooling systemdescribed above in connection with FIG. 3.

Another significant difference in the assembly configuration of FIG. 4is the provision of a fill and drain pump 401 and associated check valve402, integrated within the cooling system and coupled, for instance, inparallel with the primary coolant pump(s) 335′. As explained furtherbelow, integrating the fill and drain pump into the cooling system ofthe cooled electronic assembly provides numerous advantages, including,for instance, allowing the fill and drain pump to operate as a backupcoolant pump to the primary coolant pump(s) upon detection of an errorin the primary coolant pump(s) to ensure continued circulation ofcoolant through the coolant circulation loop of the cooling system.Further, integrating the fill and drain pump into the cooling systemallows for the control system or controller of the cooling system toadvantageously monitor one or more aspects of the cooling system duringthe selective coolant filling of the cooling system, or the coolantdraining of the cooling system to, for instance, automaticallydeactivate the fill and drain pump, or provide a warning to servicepersonnel performing the fill or drain process upon detection of aproblem or error in the cooling system. By way of example, the one ormore aspects or parameters being monitored by the control system mayinclude one or more of coolant level within the cooling system, acurrent level being drawn by the fill and drain pump during the fill ordrain operation, and/or a potential coolant leak from the coolingsystem.

Generally stated, disclosed herein are cooling systems, cooledelectronic assemblies, and methods of fabrication, which include anintegrated fill and drain pump. For instance, a cooling system forcooling one or more electronic components may include a coolantcirculation loop, at least one primary coolant pump, and a fill anddrain pump. The primary coolant pump(s) is coupled to facilitatecirculating coolant through the coolant circulation loop, and the filland drain pump is provided to facilitate selective filling of thecooling system with the coolant, or draining of the coolant from thecooling system. The fill and drain pump is integrated within the coolingsystem as a backup coolant pump to the at least one primary coolantpump, and the fill and drain pump circulates the coolant through thecoolant circulation loop responsive to an error in the at least oneprimary coolant pump.

In one or more implementations, the primary coolant pump(s) comprises afirst type of coolant pump, and the fill and drain pump comprises asecond type of coolant pump, different from the first type of coolantpump. For instance, the first type of coolant pump may include or be acentrifugal-type pump or centripetal-type pump, and the second type ofpump may be or include a positive displacement-type pump, or moregenerally, a self-priming-type coolant pump.

In certain implementations, the cooling system further includes acontrol system which controls the primary coolant pump(s) and the filland drain pump. The control system automatically activates the fill anddrain pump based on detection of the error in the primary coolantpump(s). Additionally, the control system monitors the cooling systemduring the selective filling of the cooling system with the coolant,and/or monitors the cooling system during the draining of the coolantfrom the cooling system. In one or more embodiments, the cooling systemmay include multiple primary coolant pumps coupled to the coolantcirculation loop in parallel, and the control system automaticallyactivates the fill and drain pump if an error is detected in eachprimary coolant pump of the multiple primary coolant pumps.

In another aspect, the cooling system further includes at least onecoolant filter associated with the at least one primary coolant pump.The coolant filter(s) may be in or extend into a hose connecting theprimary coolant pump(s) in fluid communication with the coolantcirculation loop, for instance, at a coolant outlet, or downstream ofthe coolant outlet, of the primary coolant pump(s). Advantageously, thefilter is sized to protect components of the cooling system from debrisclogging, either, for instance, within channels of the coolingassemblies associated with the electronic systems, or, for instance,from interfering with quick connect couplings or the vacuum breakerseals.

As noted, in certain implementations, the cooling system includes acontrol system which automatically monitors the selective filling of, orthe selective draining of, the cooling system, by monitoring one or moreparameters or aspects of the cooling system during the coolant fillprocess or a coolant drain process, respectively, of the cooling systemusing, in part, the fill and drain pump. For instance, the one or moreparameters may include one or more of coolant level within the coolingsystem, current being drawn by the fill and drain pump (indicative ofwhether coolant or air is passing through the pump), and/or coolantleakage from the cooling system. The control system may automaticallyissue a warning, or automatically deactivate the fill and drain pumpupon detection of an issue with the one or more aspects of the coolingsystem being monitored during the coolant fill process or the coolantdrain process.

In one or more embodiments, the cooling system may further include aheat exchange assembly coupled in fluid communication with the coolantcirculation loop to dissipate heat from the coolant passingtherethrough. The coolant circulation loop may include a coolant returnmanifold, or more specifically, a multifunction coolant manifoldstructure (such as disclosed herein), wherein the primary coolantpump(s) and the fill and drain pump are coupled in parallel-fluidcommunication between the multifunction coolant manifold structure andthe heat exchange assembly. The multifunction coolant manifold structuremay be combined with the above-noted implementations of the coolingsystem and include, in one embodiment, a coolant commoning manifold andan auxiliary coolant reservoir, which may be disposed above and in fluidcommunication with the coolant commoning manifold. The coolant commoningmanifold is sized to slow flow of coolant exhausting from the multiplecooling assemblies to allow gas within the exhausting coolant to escapethe coolant within the coolant commoning manifold. The multifunctioncoolant commoning manifold is configured for the escaping gas (e.g., airbubbles) to rise to the auxiliary coolant reservoir, and be replacedwithin the coolant commoning manifold by coolant from the auxiliarycoolant reservoir.

In certain implementations, the multifunction coolant manifold structureis a single, integrated and rigid structure, where the auxiliary coolantreservoir is integrated with the coolant commoning manifold. In thisconfiguration, the coolant commoning manifold may have a largerdimension in a first direction, such as the vertical direction, comparedwith that of the auxiliary coolant reservoir, which may have a largerdimension in a second direction, such as the horizontal direction. Thus,in one embodiment, the coolant commoning manifold may be an elongate,vertical manifold, and the auxiliary coolant reservoir may have a largercross-sectional area in a horizontal direction to accommodate additionalcoolant.

In one or more other implementations, the auxiliary coolant reservoirmay be coupled in fluid communication with the coolant commoningmanifold via a detachable coolant conduit or hose. In thisconfiguration, the coolant commoning manifold may have the same size as,or have a larger volume than, the auxiliary coolant reservoir.Alternatively, in one or more implementations, the auxiliary coolantreservoir may have a larger volume of coolant than the coolant commoningmanifold. Also note that, in one or more embodiments, the coolantcommoning manifold may have a coolant volume twice or larger the size ofthe coolant volume of the coolant supply manifold of the cooling system.

In one or more embodiments, the multifunction coolant manifold structuremay include a detachable, field-replaceable unit, which includes theauxiliary coolant reservoir. Further, the field-replaceable unit mayinclude one or more components for at least one of monitoring andcontrolling one or more characteristics of the coolant within themultifunction coolant manifold structure, and hence within the coolingsystem. By way of example, the one or more components may include one ormore coolant level sensors (for sensing a level of coolant within themanifold structure); one or more vacuum breakers (to prevent cavitationwithin the pumping assembly of the cooling system); and/or one or morepressure relief valves (to ensure that the cooling system does notover-pressurize), etc. Advantageously, by associating these componentswith a field-replaceable unit, the one or more components may be readilyremoved for servicing or replacement by exchanging out thefield-replaceable unit of the multifunction coolant manifold structure.Further, by sizing the coolant commoning manifold as discussed herein,and by locating the field-replaceable unit above the coolant commoningmanifold, the field-replaceable unit may be replaced while the coolingsystem is operational, that is, while coolant continues to be pumpedthrough the cooling system to cool the electronic systems. This can beaccomplished, in part, by utilizing quick disconnect couplings inassociation with the detachable coolant conduit coupling the auxiliarycoolant reservoir to the coolant commoning manifold.

By way of example, FIGS. 5A & 5B depict one detailed embodiment of apartially assembled, cooled electronic assembly, in accordance with oneor more aspects of the present invention. In the depicted embodiment,the cooled electronic assembly includes a cooling system housing 500,which may be configured for disposition within, for instance, a lowerportion of an electronics rack, such as within one or more of theabove-described electronics racks. As illustrated, the cooled electronicassembly also includes multiple electronic systems 301 to be cooled. Inthe configuration of FIG. 5A, the electronic systems are shown one abovethe other, above cooling system housing 500, as they might be positionedwithin an electronics rack. Note, however, that this particularconfiguration is presented as one example only. Electronic systems 301each have associated therewith a cooling assembly (not shown), such asone or more coolant-cooled heat sinks, cold plates, immersion-coolinghousings, etc., which facilitate extraction of heat from the respectiveelectronic system, or from one or more electronic components within therespective electronic system.

As illustrated in FIG. 5A, the coolant circulation loop of the coolingsystem includes, in the depicted embodiment, a coolant supply manifold310, which includes respective quick connect couplings 501 thatfacilitate connection of appropriately sized and configured hoses 503 tothe coolant supply manifold 310, so as to couple in fluid communicationthe coolant supply manifold and the cooling assemblies associated withthe electronic systems 301. Similar hoses 505 and quick connectcouplings 502 are associated with the multifunction coolant manifoldstructure 400 of the cooling system's coolant circulation loop forcoupling the cooling assemblies associated with the electronics systems301 in parallel fluid communication with manifold structure 400 as well.

As illustrated in FIG. 5A, the multifunction coolant manifold structureincludes a coolant-commoning manifold 320′ from which quick connectcouplings 502 extend. In one embodiment, coolant-commoning manifold 320′is sized larger than coolant supply manifold 310 (e.g., 2× larger orgreater in coolant volume) to, in part, slow a flow rate of coolantexhausting from the cooling assemblies associated with the electronicsystems 301 as the coolant enters the coolant-commoning manifold 320′.This slowing of the coolant flow rate is designed so that entrained airor gas within the coolant is allowed to escape within thecoolant-commoning manifold 320′ and rise, in one embodiment, toauxiliary coolant reservoir 323′ located above coolant-commoningmanifold 320′, and in fluid communication therewith.

In the example of FIGS. 5A & 5B, the multifunction coolant manifoldstructure 400 is a single, integrated and rigid structure, with thecoolant-commoning manifold 320′ and auxiliary coolant reservoir 323′ influid communication within the integrated structure. As escaping air orgas rises to the auxiliary coolant reservoir 323′ from thecoolant-commoning manifold 320′, it is replaced within thecoolant-commoning manifold 320′ by coolant from the auxiliary coolantreservoir 323′. That is, as air or gas rises, coolant drops from theauxiliary coolant reservoir 323′ into the coolant-commoning manifold320′. In this manner, the multifunction coolant manifold structure 400inherently functions as a de-aerator. Further, a coolant expansionregion is defined in an upper portion of auxiliary coolant reservoir323′ by providing, for instance, a coolant fill port 328′ in associationwith the auxiliary coolant reservoir on a side of the reservoir, spacedbelow an upper-most (or top) of the auxiliary coolant reservoir 323′. Inthis manner, a volume of air (that is, an air pocket) is formed abovethe coolant fill port 328′ within the auxiliary coolant reservoir. Thisvolume of air advantageously allows for safe expansion and contractionof the coolant within the cooling system due, for instance, to changingtemperatures or pressures.

As illustrated in FIGS. 5A & 5B, the multifunction coolant manifoldstructure 400, and in particular, the auxiliary coolant reservoir 323′portion thereof, includes connections for one or more components to atleast one of monitor or control one or more characteristics of thecoolant within the multifunction coolant manifold structure. These oneor more components may include, for instance, one or more upper andlower coolant level sensors 324′ for sensing level of coolant within themultifunction coolant manifold structure 400, and reporting the level toa control system or controller (not shown) for use in possible controlaction. For instance, should the level of coolant within themultifunction coolant manifold structure drop to an unacceptably lowlevel, the level sensor(s) 324′ signals could be employed by thecontroller to signal service personnel to add coolant to the system.Alternatively, depending on the sensed level, the controller couldautomatically shut the cooling system down, and depending on theimplementation, possibly shut the electronic systems down as well. Thismight depend, for instance, on whether backup cooling, such as backupairflow cooling, is integrated within the cooled electronic assembly.Additionally, the component connections may allow for connections of oneor more vacuum breakers 325′, and/or one or more pressure-relief valves326′, as described above.

Note that FIGS. 5A & 5B depict one embodiment only of an multifunctioncoolant manifold structure 400, configured as an integrated structure,wherein the above-described components or facilities are advantageouslyintegrated into a common, multipurpose structure. By way of example, themultifunction coolant manifold structure may be fabricated of a single,punched, stainless steel sheet metal stamping, which is bent into theappropriate shape and robotically welded to arrive at the desiredstructure. The illustrated manifold structure 400 is used to common theexhaust flow from the parallel-coupled cooling structures associatedwith the electronic systems. In one implementation, these could beparallel computer nodes or server nodes of an electronics rack, withfour electronic systems being illustrated in FIGS. 5A & 5B, by way ofexample only.

As noted, the upper portion of the multifunction coolant manifoldstructure is advantageously configured as an auxiliary coolantreservoir. In one or more implementations, the cross-sectional area ofthe auxiliary coolant reservoir 323′ is larger than the cross-sectionalarea of the coolant-commoning manifold 320′. In particular, in thedepicted implementation, the coolant-commoning manifold 320′ has alarger dimension in a first, vertical direction compared with that ofthe auxiliary coolant reservoir 323′, but that the auxiliary coolantreservoir 323′ has a larger horizontal dimension in a second directioncompared with that of the coolant-commoning manifold 320′. Note that thespecific configuration of auxiliary coolant reservoir 323′ is presentedby way of example only. The size and configuration of the multifunctioncoolant manifold structure may depend, in part, on the available sizewithin the associated electronics assembly or electronics rack to whichthe cooling system provides cooling.

Note also that, in one embodiment, the coolant-commoning manifold 320′cross-section is made larger than normally required to carry the coolantflow (for instance, 2× or larger) in order to allow the returning,exhausting coolant to slow down, allowing air and other gas in thecoolant to de-aerate, or come out of solution, within thecoolant-commoning manifold, with any gas bubbles rising to the auxiliarycoolant reservoir portion at the top of the manifold structure, whilecoolant from the reservoir replaces the gas bubbles from thecoolant-commoning manifold. Note that the multifunction coolant manifoldstructure further may incorporate, for example, in association with theauxiliary coolant reservoir, one or more level sensors, to allow thecooling system controller to know the current coolant level state, andtake or signal for action, if required.

Additionally, features or connections may be provided in themultifunction coolant manifold structure, such as, in association withthe auxiliary coolant reservoir (in one embodiment), to facilitateinstalling vacuum breakers 325′ and/or pressure-relief devices 326′. Thevacuum breaker(s) ensures that the auxiliary coolant reservoir is nearatomospheric or slightly negative pressure. This feature may be employedto prevent the pumps from cavitating due to a negative pressure in thesystem. The pressure-relief valves may be provided as a safety feature.These devices and valves are placed, in one embodiment, in the auxiliarycoolant reservoir, at the highest coolant location within the coolingsystem. This ensures that, even if the devices fail in an open state, nocoolant will escape since the coolant is under little or no pressurewithin the multifunction coolant manifold structure. During normaloperation, the devices can fail in place, and not cause any functionalproblems with the cooling system disclosed herein. The component(s) canalso be safely removed while the cooling system is operational. Notethat in the embodiment of FIGS. 5A & 5B, the vacuum breaker devices 325′and pressure-relief valves 326′ are located in the upper-most portion ofthe auxiliary coolant reservoir 323′.

Mounting brackets may be provided to facilitate convenient mounting ofthe coolant supply manifold and multifunction coolant manifold structureinto the electronics rack or frame. In one implementation, themultifunction coolant manifold structure is filled with coolant, as isthe rest of the cooling system, prior to starting the pumping assembly.The reservoir 323′ is, in one implementation, sized with a sufficientvolume of coolant to ensure that if an unfilled cooling structureassociated with one of the electronics systems is connected to thecooling system during operation, there will be sufficient coolant withinthe cooling system to continue operation. Note that in the embodimentpresented, a large volume of coolant exists above the multipleparallel-coupled pumps, ensuring a good source of coolant to prime thepumping units.

As shown in the figures, the multifunction coolant manifold structure400 further includes a coolant distribution manifold portion withcoolant distribution connections 507, 507′ (FIG. 5B), which allowcoolant hoses 512, 512′ (FIG. 5A) to couple to the manifold structure toreceive coolant from the multifunction coolant manifold structure 400for distribution to the multiple pumping units, such as theabove-described primary coolant pumps 335′, and fill and drain pump 401.In the embodiment of FIG. 5A, two primary coolant pumps 335′, orredundant pumping units (RPUs), are illustrated by way of example only,each receiving coolant (via the respective hose connection 507 and hose512) when active from the multifunction coolant manifold structure 400.In one implementation, the parallel-coupled primary coolant pumps 335′operate to independently pump coolant through a return manifold (notshown) to a heat removal section 350′ (as described above), which mayalso be disposed within the cooling system housing 500, for instance,behind the primary coolant pumps 335′. In one implementation, the heatremoval section 350′ may comprise one or more coolant-to-air heatexchangers, with air being drawn through the cooling system housing 500via one or more fan mechanisms 510, which in one embodiment, may also bedisposed within the housing 500, for instance, behind the one or morecoolant-to-air heat exchangers. In the depicted embodiment, a common airplenum 511 may be defined between the fan mechanisms 510 to facilitatebalanced airflow through the cooling system housing 500, and thus acrossthe heat removal section 350′. In one or more implementations, the fanmechanism 510 may comprise centrifugal fans or blowers, with four fanmechanisms being depicted in the embodiment of FIG. 5A, by way ofexample only. Note that in an alternate embodiment, the heat removalsection 350′ could include one or more liquid-to-liquid heat exchangersto reject heat from the coolant circulating through the cooling systemto, for instance, facility-chilled liquid, such as building-chilledwater. The heat removal section is coupled to coolant supply manifold310 via a hose 520 and appropriate connections.

As noted, in another aspect of the cooling system and cooled electronicassemblies disclosed herein, a fill and drain pump 401 is integratedwithin the cooling system and disposed, for instance, within coolingsystem housing 500. In one or more implementations, fill and drain pump401 is integrated within the cooling system for use during a coolantfill process or a coolant drain process, as well as to operate as abackup coolant pump to the one or more primary coolant pumps. Forinstance, should an error condition be detected in the primary coolantpump(s) 335′, then the control system of the cooling system may beconfigured or programmed to automatically activate the fill and drainpump to continue circulating coolant through the coolant circulationloop in a failsafe mode until service personnel may service the coolingsystem.

By way of example, the primary coolant pumps 335′ may each be orcomprise a centrifugal-type pump or centripetal-type pump, and the filland drain pump 401 may be, for instance, a positive displacement-typepump. Coolant hoses 512′ coupled to fill and drain pump 401 may includequick connect couplings to allow for the different uses of the fill anddrain pump described herein, that is, to facilitate a coolant fillprocess, a coolant drain process, as well as to allow for the fill anddrain pump 401 to be coupled as a failsafe pump in parallel-fluidcommunication with the primary coolant pumps 335′ when the cooledelectronic assembly is in normal operation. For instance, in normaloperation, the fill and drain pump 401 is coupled in parallel-fluidcommunication with primary coolant pumps 335′ between multifunctioncoolant manifold structure 400 and the return manifold at the inlet toheat removal section 350′. In addition, as illustrated in FIG. 5A, oneor more leak sensor(s) 506 may be provided within the cooling systemassociated with, for instance, one or more system coolant pans locatedbelow the cooling system, in a lower portion of the cooled electronicassembly. The leak sensor(s) 507 may be coupled to a control system orcontroller, described below, which monitors for potential coolantleakage within the system and initiates in response thereto one or moreautomatic processes.

Note that in the implementation depicted, multiple drive cards 530 areemployed, by way of example. Drive cards 530 power and control operationof, for instance, the primary coolant pumps 335′, the fill and drainpump 401, as well as the fan mechanisms 510, as directed, for instance,by the control system of the cooling system.

FIG. 6 is a partial cross-sectional elevational view of the coolingsystem of FIG. 5A, shown in operation, and illustrating a coolingairflow 600 being drawn across a coolant-to-air heat exchanger withinthe heat removal section of the cooling system. Cooling airflow 600 maybe drawn from an air inlet side to an air outlet side of the cooledelectronic assembly employing multiple fan mechanisms 510, such asmultiple centrifugal fans, which may draw air from common airflow plenum511 near or at the air outlet side of the cooled electronic assembly.

FIG. 7 is a schematic of the cooling system described above inconnection with FIGS. 5A-6, wherein various components of the coolingsystem are designated as either concurrently field-replaceable units(CF) or non-concurrently field-replaceable units (NCF). As illustrated,in one embodiment, the primary coolant pumps 335′, centrifugal fans 510,motor drive assemblies (MDA) 530, fill and drain pump 401, leaksensor(s) 506, coolant temperature sensor(s) 700, and various sense andpower cables to motor drive assemblies 530, may each be concurrentlyfield-replaceable units in a cooling systems such as described herein.For instance, while one motor drive assembly 530 is driving one primarycoolant pump 335′ and two centrifugal fans 510, the remainingconcurrently field-replaceable motor drive assembly, primary coolantpump fill and drain (F/D) pump and centrifugal fans may be replaced. Inthe depicted embodiment, only supply manifold 310, heat removal section350′, and multifunction coolant manifold structure 400, arenon-concurrently field-replaceable units. Note that the level sensorsassociated with multifunction coolant manifold structure 400 may beprovided as redundant sensors. For instance, there may be redundantupper coolant level sensors, as well as redundant lower coolant levelsensors. In one or more implementations, the control system oversees theoperation of the cooling system by receiving sensed parameters, as wellas by activating or deactivating, for instance, one or more of primarycoolant pumps 335′, motor drive assemblies 530, fill and drain pump 401,and centrifugal fans 510, based, for instance, on whether a coolant fillprocess, a coolant drain process, or normal operational mode, are ineffect as explained further below.

FIG. 8A is an operational schematic of one embodiment of the cooledelectronic assembly of FIGS. 5A & 6, in accordance with one or moreaspects of the present invention. As illustrated, the cooled electronicsystem includes multiple electronic systems 301, each of which may have,in one embodiment, an associated cooling assembly of a cooling system,such as described herein. As noted, in one or more embodiments, thecooling assemblies may comprise one or more coolant-cooled heat sinks,cold plates, immersion-cooling housings, etc., which facilitateextraction of heat from the respective electronics system, or from oneor more electronic components within the respective electronics system.As illustrated, the cooling assemblies associated with the electronicsystems 301 may be coupled in parallel-fluid communication betweencoolant supply manifold 310 and a coolant return manifold, such as theabove-described multifunction coolant manifold structure 400. Thecooling system's coolant circulation loop further includes, in oneexample, redundant primary coolant pumps 335′ coupled in parallel-fluidcommunication between multifunction coolant manifold structure 400 and areturn or commoning manifold 340′ at the inlet to heat removal section350′. By way of example, heat removal section 350′ may include one ormore coolant-to-air heat exchangers, and multiple associated fanmechanisms 510 (e.g., centrifugal fans) may be provided to draw anairflow 600 across the heat removal section, transferring heat from thecirculating coolant within the cooling system to the airflow 600 passingacross heat removal section 350′. The cooled coolant is then returned tothe coolant supply manifold 310 to continue circulation within thecoolant circulation loop. As noted above, the heat removal section 350′could comprise, in another embodiment, one or more coolant-to-coolantheat exchangers or liquid-to-liquid heat exchangers to reject heat fromthe coolant circulating through the coolant circulation loop of thecooling system to a facility coolant. For instance, heat could berejected to facility-chilled water where available, rather than tocooled air 600. Quick connect couplings 501, 502, 507, 507′, 801 may beused within the cooling system to facilitate coupling and decoupling ofthe various components of the coolant circulation loop of the coolingsystem, as illustrated.

As explained above, the multifunction coolant manifold structure 400 mayinclude a reservoir 323′ in an upper portion thereof, which includes,for instance, a coolant fill port 328′, redundant upper and lowercoolant level sensors 324′, one or more vacuum breakers 325′, and one ormore pressure-relief valves 326′. The level sensors provide signals, inone embodiment, to redundant motor drive assemblies 530 controlled bycontrol system 820 of the cooling system. As illustrated, in oneembodiment, each motor drive assembly 530 is associated with arespective primary coolant pump 335′. In addition to monitoring thelevel sensors, the motor drive assemblies 530 also monitor, in oneembodiment, system level leak sensors 811 associated, for instance, witha system leak pan 810 disposed in a lower portion of the cooledelectronic assembly, as well as monitor redundant temperature sensors812 associated with the coolant supply manifold 310 to monitortemperature of the cooled coolant being returned to the coolingassemblies associated with electronic systems 301. Control system 820,which may be resident within the cooled electronic assembly or rack, orlocated elsewhere within a data center comprising the cooled electronicassembly, controls operation of the motor drive assemblies 530, forinstance, in accordance with a configured or programmed process, such asdescribed below in connection with FIG. 8B.

Before describing the control system process embodiment of FIG. 8B, notethat the primary coolant pumps 335′ may be identical, off-the-shelf, ACdriven, centrifugal or centripetal pumps. At the inlet and outlet sideof primary coolant pumps 335′, hoses, such as formed hoses, may beprovided to facilitate coupling the respective pump to the multifunctioncoolant manifold structure 400 and the return or commoning manifold 340′at the supply side to heat removal section 350′. Additionally, asillustrated, each primary coolant pump 335′ may include a coolant filter825, for instance, disposed at the coolant outlet, or downstream of thecoolant outlet, of the respective pump unit, as well as a check valve831, to prevent backflow of coolant when the respective primary coolantpump is inactive. Note that coolant filters 825 may be, in one or moreembodiments, non-replaceable filters configured to trap debris, forinstance, caused by failure of the associated primary pump unit. In oneor more embodiments, each motor drive assembly 530 is associated with arespective primary coolant pump 335′ and is able to power and controlthe associated primary coolant pump, as well as the fill and drain pump401, and one or two fan mechanisms 530, such as centrifugal fans 510.Additionally, as noted, each motor drive assembly 530 reads the leaksensors 506 located in the system pans 810 under the heat removalsection 350′, and under the coolant pumps, as well as the level sensors324′ in the auxiliary reservoir 323′, and a thermistor reading 812,reading the coolant temperature being supplied to the electronic systemsor processor drawers. In addition, each motor drive assembly mayincorporate an air inlet temperature sensor (not shown). In oneembodiment, control system 820 is configured or programmed to controlthe state of the motor drive assemblies 530.

As explained above, in operational state, a fill and drain pump 401 isalso provided in parallel-fluid communication with the primary coolantpumps 335′, between the multifunction coolant manifold structure 400 andthe return or commoning manifold 340′ at the inlet to the heat removalsection 350′. By way of example, quick connect couplings 507, 507′, 801and respective hoses may be used to couple the fill and drain pump 401in parallel-fluid communication with the primary coolant pump(s) 335′,as shown in FIG. 8A. As noted, in one embodiment, fill and drain pump401 may include a check valve 826 at the coolant outlet thereof, as wellas an in-line coolant filter (not shown), such as the above-describedcoolant filters 825 associated with the primary coolant pumps 335′. Inthe example depicted, fill and drain pump 401 is coupled in fluidcommunication to fill/drain pump 329′ via a respective quick connectcoupling 801.

Advantageously, by integrating the fill and drain pump 401 within thecooled electronic assembly, control system 820 of the cooling system mayprovide additional control and monitoring. For instance, control system820 may monitor for errors in primary coolant pumps 335′ which wouldrequire deactivation of the primary coolant pumps, and in such a case,automatically activate fill and drain pump 401 in a failsafe mode toprovide backup coolant flow through the cooling system, possibly at alower flow rate than the flow rate of coolant provided by primarycoolant pump(s) 335′. This will depend on the type of fill and drainpump employed. By employing the fill and drain pump as a backup pump ina coolant flow schematic such as depicted in FIG. 8A, minimal, if any,frequency degradation for smaller electronic systems may be encounteredupon loss of the primary coolant pumps. The fill and drain pump 401 willprovide additional time to allow service personnel to service theprimary coolant pump(s) while still allowing continued operation of thecooled electronic assembly. Further, in one or more implementations, asingle primary coolant pump may be used in parallel with a fill anddrain pump such as described herein, eliminating the need for redundantprimary coolant pumps.

FIG. 8B depicts one embodiment of system control processing 830implemented by control system 820 of a cooled electronic assembly, suchas disclosed herein. In the depicted processing embodiment, the controlsystem or controller determines whether at least one primary coolantpump is running with no error present, where a no error state means thatthe primary coolant pump is “good” 832. The control system obtainsstatus for each primary coolant pump. The status includes the state ofthe primary coolant pump, that is, whether in a “good” or “bad” state,and on time 834. The associated motor drive assembly 530 (FIG. 8A) ofthe primary coolant pump 335′ (FIG. 8A) may identify various types oferrors including, for instance, coolant pump over and/or under current,coolant pump over and/or under rotating, fan mechanism faults, leakdetected, dry auxiliary coolant reservoir, that is, both level sensorsdry, a voltage test point error(s), or a non-valid temperature sensor.

Processing inquires whether any “good” primary coolant pump is nowshowing an error state 836, and if “yes”, the control system marks theerrored primary coolant pump as “bad”, and posts an appropriatereference code for the primary coolant pump 838. If no “good” primarycoolant pump is showing error, or if so, after the primary coolant pumphas been marked “bad”, the control system determines whether one “good”primary coolant pump remains running 840. If “yes”, then processingdetermines whether an overlap period has expired 842. Note that theoverlap period is selected to allow any recently turned on primarycoolant pump to speed up and potentially reveal any defects before thepreviously “bad” state or “good” state primary coolant unit is turnedoff. This ensures that the next primary coolant pump to operate isfunctioning well before the present primary coolant pump is turned off.By way of example, an overlap period on the order of ten minutes may besufficient for this purpose. Note that in one or more embodiments, thecontrol system may perform periodic switch-over processing, where a next“good” primary coolant pump is turned on after the switch-over periodhas expired, for instance, after a certain number of hours of running.If the overlap period has not expired, processing returns to determinewhether at least one primary coolant pump is running with no errorpresent 832. Otherwise, the “bad” primary coolant pump is turned off,with the “good” primary coolant pump remaining running, having theshortest “on” timer, that is, any other “good” primary coolant pump(s),in the case of more than two primary coolant pumps, are turned off 844,before processing repeats.

Assuming that more than one “good” primary coolant pump is not currentlyrunning 840, then processing determines whether the errored “bad”primary coolant pump is running 846. If “no”, then no action is takenand processing repeats. If “yes”, then the control system determineswhether any “good” primary coolant pumps are available 848. If “yes”, anext “good” primary coolant pump is activated 850, meaning that morethan one primary coolant pump is currently running 852, and processingreturns to determine whether at least one primary coolant pump runninghas no error present 832.

If no “good” primary coolant pumps are available, then the controlsystem turns on or activates the failsafe, integrated fill and drainpump 854, and posts an integrated fill and drain pump in failsafereference code 856. This reference code may trigger one or more serviceprocesses, such as a service process to be performed by a servicetechnician to repair/service the error states, such as turning offmarked “bad” parts and allow their replacement, after which serviceprocesses may clear the errors and restore the affected parts to “good”state.

Advantageously, integrating the fill and drain pump within the cooledelectronic assembly such as described herein allows for monitoring bythe control system of the cooling system during a coolant fill processor a coolant drain process. For instance, during a coolant fill processor coolant drain process, the control system may monitor coolant levelsvia the level sensors, as well as one or more pump characteristics, suchas one or more characteristics of the fill and drain pump, or one ormore characteristics of the primary coolant pump(s). In addition, thecontrol system may be used to monitor coolant top-offs and/or filling ofone or more field-replaceable units exchanged into the cooling system.

FIG. 9 is a partial depiction of a cooled electronic assembly such asdescribed above in connection with FIGS. 5A, 6 & 8A, as well as acontainer 900 for containing liquid coolant to be provided to, ordrained from, the cooled electronic assembly. As illustrated, in one ormore embodiments, redundant primary coolant pumps 335′ may be coupled inparallel-fluid communication between multifunction coolant manifoldstructure 400 such as described herein (or more generally, a coolantreturn manifold), and a commoning manifold 340′ at the coolant inletside to the heat removal section, such as the above-described heatexchanger(s). As noted, in one embodiment, multifunction coolantmanifold structure 400 includes a quick connect coupling 507′ to themanifold, and a fill/drain port 328′ in the auxiliary coolant reservoir,disposed in the uppermost portion of the manifold. Further, a quickconnect coupling 801 is provided in commoning manifold 340′ which is, inone or more embodiments, disposed at a lowest point in the coolingsystem (i.e., at the above-described fill/drain port 329′). Hoses 901and 902 of appropriate diameter and length are coupled to the fill anddrain pump 401, which as noted above, is integrated within the cooledelectronic assembly. Coolant container 900 includes an air hose 903attached to the container as well. Quick connect couplings may beprovided at the ends of hoses 901, 902, 903 to facilitate establishingthe connections described herein.

FIG. 10A depicts one configuration for a coolant fill process using theassembly of FIG. 9. As illustrated, hose 902 is coupled to quick connectcoupling 507′ at the lower region of manifold 400, and hose 901 iscoupled to container 900 containing the coolant. Air hose 903 couplescontainer 900 to bleed or fill port 328′. With these connections made,the control system controls activating and deactivating of pumps withinthe cooled electronic assembly, as well as monitoring of varioussensors, such as the coolant level sensors described above.

FIG. 10B depicts one embodiment of control system control and monitoringof a coolant fill process using, for instance, the assembly of FIG. 10A.After personnel have connected the hoses described above to allow forthe coolant fill process as shown in FIG. 10A 1000, the control systemactivates the fill and drain pump 1002, and waits a first time delay(such as 10 minutes) sufficient to allow the fill and drain pump, suchas a positive displacement pump, to pump coolant into the cooling systemfrom the container. After the first time delay, the control systemactivates a primary coolant pump, such as a first primary coolant pump1004, and waits a second time delay, for instance, five minutes, toallow the coolant to circulate throughout the cooling system. The firstprimary coolant pump is then deactivated 1006, and the second primarycoolant pump is activated 1008, after which the control system waits afurther, second time interval, such as five minutes, to allow coolant tocirculate through the second primary coolant pump and the coolingsystem, after which the second primary coolant pump is deactivated 1010,and the control system waits a further delay, such as one minute, beforedeactivating the fill and drain pump 1012. After deactivating the pumps,the control system checks the coolant level sensors 1014 to determinewhether the sensors indicate that the cooling system is full 1016. If“yes”, then a ‘procedure successful’ message is sent, for instance, to arepair and verify service panel associated with the cooled electronicassembly 1018. Thereafter, the hose connections are changed to theirdefault position, with the fill and drain pump coupled in parallel withthe primary coolant pumps, as described above in connection with FIGS.5A, 6 & 8A 1020.

If the sensors indicate the system is not full, then the control system,in one or more embodiments, issues a warning and prompts servicepersonnel to check hose connections and coolant supply level 1025. Notethat in one or more embodiments, the coolant fill process is configuredahead of time to ensure that, if working properly, coolant levels shouldbe at the desired system full level upon completion of the timed coolantpumping provided by the fill and drain pump, first primary coolant pump,and second primary coolant pump. Once the warning has been issued andthe service personnel has checked hose connections and coolant supplylevel, then the coolant fill process may be repeated, if desired.

During the coolant fill process, the control system is monitoring forvarious conditions, which may require automatic action to be taken. Forinstance, the coolant fill process may be stopped and a warningtriggered, should the level sensor change from a wet state to a drystate during the coolant fill process 1030. If “yes”, then the fill anddrain pump is deactivated 1032 and a warning is issued 1025. Also, ifthe fill and drain pump current is decreased during the coolant fillprocess 1040, the control system automatically deactivates the fill anddrain pump 1042 and issues a warning 1025. The fill and drain pumpcurrent decreasing may indicate a lack of coolant supply. The controlsystem also monitors the leak sensors and determines whether a coolantleak is detected. If “yes”, the fill and drain pump is deactivated 1052and the control system may issue a warning and prompt the servicepersonnel to check for leaks 1054.

FIG. 11A depicts one configuration for a coolant drain process using theassembly of FIG. 9. As illustrated, hose 902 is coupled to quick connectcoupling 801 at the fill/drain port 329′ of commoning manifold 340′ atthe coolant inlet side to the heat removal section, and hose 901 iscoupled to container 900, which is to receive coolant being drained fromthe cooling system. Hose 903 couples container 900 as illustrated to thebleed or fill port 328′. With these connections made, the control systemcontrols activating and deactivating of the pumps within the cooledelectronic assembly, as well as monitoring of various sensors, such asthe sensors described above, to facilitate to coolant draining process.

FIG. 11B depicts one embodiment of the control system control andmonitoring of coolant drain processing using, for instance, the assemblyof FIG. 11A. The hoses are connected to allow for the drain process1100. In addition, cooling system pumps are off, and the coolant levelsensors are being monitored by the control system 1102. The controlsystem activates the fill and drain pump 1104, and waits a first timedelay, such as ten minutes, to allow the fill and drain pump to pumpcoolant from the cooling system into the container. After the first timedelay, the control system inquires whether the fill and drain pumpcurrent level indicates that the fill and drain pump is pumping air1106. If “no”, then the control system waits a second time delay, forinstance, five minutes, to allow the fill and drain pump to continue todrain coolant from the cooling system 1108. Once the fill and drain pumpcurrent level indicates that the fill and drain pump is pumping air,then the fill and drain pump is deactivated 1110, and the control systemdetermines whether system coolant level state is at the desired state1112. If “yes”, then a ‘procedure successful’ message is sent, forinstance, to a repair and verify service panel associated with thecooled electronic assembly 1114. Otherwise, a ‘try again message?’ maybe sent to the repair and verify service panel, prompting servicepersonnel to potentially initiate a repeat of the coolant drain process,if desired 1116.

Referring to FIG. 12, in one example, a computer program product 1200includes, for instance, one or more non-transitory computer readablestorage media 1202 to store computer readable program code means, logicand/or instructions 1204 thereon to provide and facilitate one or moreembodiments.

The control aspects present invention may be a system, a method, and/ora computer program product. The computer program product may include acomputer readable storage medium (or media) having computer readableprogram instructions thereon for causing a processor to carry outaspects of the present invention.

The computer readable storage medium can be a tangible device that canretain and store instructions for use by an instruction executiondevice. The computer readable storage medium may be, for example, but isnot limited to, an electronic storage device, a magnetic storage device,an optical storage device, an electromagnetic storage device, asemiconductor storage device, or any suitable combination of theforegoing. A non-exhaustive list of more specific examples of thecomputer readable storage medium includes the following: a portablecomputer diskette, a hard disk, a random access memory (RAM), aread-only memory (ROM), an erasable programmable read-only memory (EPROMor Flash memory), a static random access memory (SRAM), a portablecompact disc read-only memory (CD-ROM), a digital versatile disk (DVD),a memory stick, a floppy disk, a mechanically encoded device such aspunch-cards or raised structures in a groove having instructionsrecorded thereon, and any suitable combination of the foregoing. Acomputer readable storage medium, as used herein, is not to be construedas being transitory signals per se, such as radio waves or other freelypropagating electromagnetic waves, electromagnetic waves propagatingthrough a waveguide or other transmission media (e.g., light pulsespassing through a fiber-optic cable), or electrical signals transmittedthrough a wire.

Computer readable program instructions described herein can bedownloaded to respective computing/processing devices from a computerreadable storage medium or to an external computer or external storagedevice via a network, for example, the Internet, a local area network, awide area network and/or a wireless network. The network may comprisecopper transmission cables, optical transmission fibers, wirelesstransmission, routers, firewalls, switches, gateway computers and/oredge servers. A network adapter card or network interface in eachcomputing/processing device receives computer readable programinstructions from the network and forwards the computer readable programinstructions for storage in a computer readable storage medium withinthe respective computing/processing device.

Computer readable program instructions for carrying out operations ofthe present invention may be assembler instructions,instruction-set-architecture (ISA) instructions, machine instructions,machine dependent instructions, microcode, firmware instructions,state-setting data, or either source code or object code written in anycombination of one or more programming languages, including an objectoriented programming language such as Smalltalk, C++ or the like, andconventional procedural programming languages, such as the “C”programming language or similar programming languages. The computerreadable program instructions may execute entirely on the user'scomputer, partly on the user's computer, as a stand-alone softwarepackage, partly on the user's computer and partly on a remote computeror entirely on the remote computer or server. In the latter scenario,the remote computer may be connected to the user's computer through anytype of network, including a local area network (LAN) or a wide areanetwork (WAN), or the connection may be made to an external computer(for example, through the Internet using an Internet Service Provider).In some embodiments, electronic circuitry including, for example,programmable logic circuitry, field-programmable gate arrays (FPGA), orprogrammable logic arrays (PLA) may execute the computer readableprogram instructions by utilizing state information of the computerreadable program instructions to personalize the electronic circuitry,in order to perform aspects of the present invention.

Aspects of the present invention are described herein with reference toflowchart illustrations and/or block diagrams of methods, apparatus(systems), and computer program products according to embodiments of theinvention. It will be understood that one or more blocks of theflowchart illustrations and/or block diagrams, and combinations ofblocks in the flowchart illustrations and/or block diagrams, can beimplemented by computer readable program instructions.

These computer readable program instructions may be provided to aprocessor of a general purpose computer, special purpose computer, orother programmable data processing apparatus to produce a machine, suchthat the instructions, which execute via the processor of the computeror other programmable data processing apparatus, create means forimplementing the functions/acts specified in the flowchart and/or blockdiagram block or blocks. These computer readable program instructionsmay also be stored in a computer readable storage medium that can directa computer, a programmable data processing apparatus, and/or otherdevices to function in a particular manner, such that the computerreadable storage medium having instructions stored therein comprises anarticle of manufacture including instructions which implement aspects ofthe function/act specified in the flowchart and/or block diagram blockor blocks.

The computer readable program instructions may also be loaded onto acomputer, other programmable data processing apparatus, or other deviceto cause a series of operational steps to be performed on the computer,other programmable apparatus or other device to produce a computerimplemented process, such that the instructions which execute on thecomputer, other programmable apparatus, or other device implement thefunctions/acts specified in the flowchart and/or block diagram block orblocks.

The flowchart and block diagrams in the Figures illustrate thearchitecture, functionality, and operation of possible implementationsof systems, methods, and computer program products according to variousembodiments of the present invention. In this regard, each block in theflowchart or block diagrams may represent a module, segment, or portionof instructions, which comprises one or more executable instructions forimplementing the specified logical function(s). In some alternativeimplementations, the functions noted in the block may occur out of theorder noted in the figures. For example, two blocks shown in successionmay, in fact, be executed substantially concurrently, or the blocks maysometimes be executed in the reverse order, depending upon thefunctionality involved. It will also be noted that each block of theblock diagrams and/or flowchart illustration, and combinations of blocksin the block diagrams and/or flowchart illustration, can be implementedby special purpose hardware-based systems that perform the specifiedfunctions or acts or carry out combinations of special purpose hardwareand computer instructions.

Although various embodiments are described above, these are onlyexamples. For example, computing environments of other architectures canbe used to incorporate and use one or more embodiments. Further,different instructions, instruction formats, instruction fields and/orinstruction values may be used. Many variations are possible.

Further, other types of computing environments can benefit and be used.As an example, a data processing system suitable for storing and/orexecuting program code is usable that includes at least two processorscoupled directly or indirectly to memory elements through a system bus.The memory elements include, for instance, local memory employed duringactual execution of the program code, bulk storage, and cache memorywhich provide temporary storage of at least some program code in orderto reduce the number of times code must be retrieved from bulk storageduring execution.

Input/Output or I/O devices (including, but not limited to, keyboards,displays, pointing devices, DASD, tape, CDs, DVDs, thumb drives andother memory media, etc.) can be coupled to the system either directlyor through intervening I/O controllers. Network adapters may also becoupled to the system to enable the data processing system to becomecoupled to other data processing systems or remote printers or storagedevices through intervening private or public networks. Modems, cablemodems, and Ethernet cards are just a few of the available types ofnetwork adapters.

The terminology used herein is for the purpose of describing particularembodiments only and is not intended to be limiting. As used herein, thesingular forms “a”, “an” and “the” are intended to include the pluralforms as well, unless the context clearly indicates otherwise. It willbe further understood that the terms “comprises” and/or “comprising”,when used in this specification, specify the presence of statedfeatures, integers, steps, operations, elements, and/or components, butdo not preclude the presence or addition of one or more other features,integers, steps, operations, elements, components and/or groups thereof.

The corresponding structures, materials, acts, and equivalents of allmeans or step plus function elements in the claims below, if any, areintended to include any structure, material, or act for performing thefunction in combination with other claimed elements as specificallyclaimed. The description of one or more embodiments has been presentedfor purposes of illustration and description, but is not intended to beexhaustive or limited to in the form disclosed. Many modifications andvariations will be apparent to those of ordinary skill in the art. Theembodiment was chosen and described in order to best explain variousaspects and the practical application, and to enable others of ordinaryskill in the art to understand various embodiments with variousmodifications as are suited to the particular use contemplated.

1. A system comprising: a cooling system for cooling one or moreelectronic components, the cooling system comprising: a coolantcirculation loop; at least one primary coolant pump coupled tofacilitate circulating coolant through the coolant circulation loop; anda fill and drain pump to facilitate selective filling of the coolingsystem with the coolant, or draining of the coolant from the coolingsystem, the fill and drain pump being integrated with the cooling systemas a backup coolant pump to the at least one primary coolant pump, thefill and drain pump circulating the coolant through the coolantcirculation loop responsive to an error in the at least one primarycoolant pump.
 2. The system of claim 1, wherein the at least one primarycoolant pump comprises a first type of coolant pump, and the fill anddrain pump comprises a second type of coolant pump, the first type ofcoolant pump and the second type of coolant pump being different typesof coolant pumps.
 3. The system of claim 2, wherein the first type ofcoolant pump comprises a centrifugal-type pump or centripetal-type pump,and the second type of coolant pump comprises a positivedisplacement-type pump.
 4. The system of claim 2, wherein the secondtype of coolant pump comprises a self-priming type of coolant pump. 5.The system of claim 1, wherein the cooling system further comprises acontrol system controlling the at least one primary coolant pump and thefill and drain pump, the control system automatically activating thefill and drain pump based on detection of the error in the at least oneprimary coolant pump, and the control system monitoring the coolingsystem during the selective filling of the cooling system with thecoolant or the draining of the coolant from the cooling system.
 6. Thesystem of claim 5, wherein the cooling system comprises multiple primarycoolant pumps coupled to the coolant circulation loop in parallel, theat least one primary coolant pump being at least one primary coolantpump of the multiple primary coolant pumps, and wherein the controlsystem automatically activates the fill and drain pump based ondetection of error in each primary coolant pump of the multiple primarycoolant pumps.
 7. The system of claim 1, wherein the cooling systemfurther comprises at least one coolant filter associated with the atleast one primary coolant pump, one coolant filter of the at least onecoolant filter being disposed at or downstream of a coolant outlet ofone primary coolant pump of the at least one primary coolant pump. 8.The system of claim 1, wherein the cooling system further comprises acontrol system, the control system automatically monitoring theselective filling of the cooling system with the coolant or the drainingof the coolant from the cooling system by monitoring one or moreparameters of the cooling system during a coolant filling operation or acoolant draining operation, respectively.
 9. The system of claim 9,wherein the one or more parameters include one or more of coolant levelwithin the cooling system, current being drawn by the fill and drainpump, or coolant leakage from the cooling system, and wherein thecontrol system of the cooling system automatically issues a warning orautomatically deactivates the fill and drain pump upon detection of anerror in the one or more parameters of the cooling system beingmonitored during the coolant filling operation or the coolant drainingoperation.
 10. The system of claim 1, wherein the cooling system furthercomprises: a heat exchange assembly coupled in fluid communication withthe coolant circulation loop to dissipate heat from the coolant passingtherethrough; and wherein the coolant circulation loop further includesa coolant manifold structure, the at least one primary coolant pump andthe fill and drain pump being coupled in parallel-fluid communicationbetween the coolant manifold structure and the heat exchange
 11. Acooled electronic assembly comprising: multiple electronic systems to becooled; and a cooling system for cooling the multiple electronicsystems, the cooling system comprising: a coolant circulation loopcomprising a coolant supply manifold and a coolant return manifold;multiple cooling assemblies coupled in parallel fluid communicationbetween the coolant supply manifold and the coolant return manifold toreceive coolant from the coolant supply manifold, and exhaust coolant tothe coolant return manifold, the multiple cooling assemblies beingassociated with the multiple electronic systems to facilitate removal ofheat from the multiple electronic systems to coolant within the multiplecooling assemblies; a heat exchange assembly coupled in fluidcommunication with the coolant circulation loop to dissipate heat fromthe coolant passing therethrough; at least one primary coolant pumpcoupled to facilitate circulating coolant through the coolantcirculation loop; and a fill and drain pump to facilitate selectivefilling of the cooling system with the coolant, or draining of thecoolant from the cooling system, the fill and drain pump beingintegrated with the cooling system as a backup coolant pump to the atleast one primary coolant pump, the fill and drain pump circulating thecoolant through the coolant circulation loop based on an error in the atleast one primary coolant pump.
 12. The cooled electronic assembly ofclaim 11, wherein the at least one primary coolant pump comprises afirst type of coolant pump, and the fill and drain pump comprises asecond type of coolant pump, the first type of coolant pump and thesecond type of coolant pump being different types of coolant pumps, andwherein the second type of coolant pump comprises a self-priming type ofcoolant pump.
 13. The cooled electronic assembly of claim 12, whereinthe first type of coolant pump comprises a centrifugal-type pump orcentripetal-type pump, and the second type of coolant pump comprises apositive displacement-type pump.
 14. The cooled electronic assembly ofclaim 11, wherein the cooling system further comprises a control systemcontrolling the at least one primary coolant pump and the fill and drainpump, the control system automatically activating the fill and drainpump based on detection of the error in the at least one primary coolantpump, and the control system monitoring the cooling system during theselective filling of the cooling system with the coolant or the drainingof the coolant from the cooling system.
 15. The cooled electronicassembly of claim 14, wherein the cooling system comprises multipleprimary coolant pumps coupled to the coolant circulation loop inparallel, the at least one primary coolant pump being at least oneprimary coolant pump of the multiple primary coolant pumps, and whereinthe control system automatically activates the fill and drain pump basedon detection of error in each primary coolant pump of the multipleprimary coolant pumps.
 16. The cooled electronic assembly of claim 11,wherein the cooling system further comprises at least one coolant filterassociated with the at least one primary coolant pump, one coolantfilter of the at least one coolant filter being disposed at ordownstream of a coolant outlet of one primary coolant pump of the atleast one primary coolant pump.
 17. The cooled electronic assembly ofclaim 11, wherein the cooling system further comprises a control system,the control system automatically monitoring the selective filling of thecooling system with the coolant or the draining of the coolant from thecooling system by monitoring one or more parameters of the coolingsystem during a coolant filling operation or a coolant drainingoperation, respectively.
 18. The cooled electronic assembly of claim 17,wherein the one or more parameters include one or more of coolant levelwithin the cooling system, current being drawn by the fill and drainpump, or coolant leakage from the cooling system, and wherein thecontrol system of the cooling system automatically issues a warning orautomatically deactivates the fill and drain pump upon detection of anerror in the one or more parameters of the cooling system beingmonitored during the coolant filling operation or the coolant drainingoperation. 19-20. (canceled)